Chiller refrigeration circuit recharging apparatus and method

ABSTRACT

A portable apparatus for recharging liquid refrigerant, such as a glycol/water mixture, in a refrigeration circuit of a chiller system includes a frame, a reservoir containing the liquid refrigerant mounted to the frame, and a recharging circuit mounted to the frame. The recharging circuit is fluidly coupled to the reservoir and is configured to receive the liquid refrigerant from the reservoir. The recharging circuit comprises a filter configured to remove particulate matter from the liquid refrigerant, an air bubble separator configured to remove air bubbles from the liquid refrigerant, a pump, a flow regulating valve, and at least one outlet port configured to be fluidly coupled to the refrigeration circuit via a hose. The pump is configured to pump the liquid refrigerant from the reservoir through the filter and the air bubble separator, and into the refrigeration circuit via the hose.

FIELD OF THE INVENTION

The present invention relates generally to cooling systems, and more particularly to methods and apparatus for servicing cooling systems.

BACKGROUND OF THE INVENTION

Power converters are used to convert incoming direct current (DC) energy into alternating current (AC) energy and/or AC to DC. In solar applications, for example, the emission of solar radiation may be captured using photovoltaic cells and converted into DC power. A power conversion system, typically comprising power inverters, rectifiers, etc., converts the DC power into AC power suitable for distribution, for example, into an electric grid for use in providing power to residential and commercial buildings and other loads. Typically, power conversion systems for solar and wind power generation applications generate heat and require the use of cooling systems to maintain a suitable operating temperature range. In the case of a wind turbine, a cooling system is typically utilized to cool the power converter system for the wind turbine and to cool the oil in the wind turbine gearbox.

Such cooling systems typically are chillers using a glycol/water mixture as a refrigerant. FIG. 1 schematically illustrates an exemplary chiller 10 utilized for solar and wind power generation applications. The chiller 10 includes a refrigeration circuit 12, a heat exchanger 14, and a cooling fluid circuit 16. The refrigeration circuit 12 includes a glycol/water refrigerant that is pumped through the heat exchanger 14 to cool the cooling fluid in the cooling fluid circuit 16. The cooling fluid is utilized to cool a solar inverter, wind turbine inverter, and/or wind turbine gearbox oil.

Recharging devices are used to recharge/replace the refrigerant in these chillers. Unfortunately, these recharging devices are typically manufacturer-specific. As such, a separate recharging device is typically required for each manufacturer's chiller.

SUMMARY

It should be appreciated that this Summary is provided to introduce a selection of concepts in a simplified form, the concepts being further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of this disclosure, nor is it intended to limit the scope of the invention.

According to some embodiments of the present invention, a portable apparatus for recharging liquid refrigerant, e.g., a glycol/water mixture, in a refrigeration circuit of a chiller system includes a frame, a reservoir mounted to the frame and that contains liquid refrigerant, and a recharging circuit mounted to the frame. The recharging circuit is fluidly coupled to the reservoir and is configured to receive the liquid refrigerant from the reservoir. The recharging circuit comprises a filter configured to remove particulate matter from the liquid refrigerant, an air bubble separator configured to remove air bubbles from the liquid refrigerant, a pump, a flow regulating valve, and at least one outlet port configured to be fluidly coupled to the refrigeration circuit via a hose. The pump is configured to pump the liquid refrigerant from the reservoir through the filter and the air bubble separator, and into the refrigeration circuit via the hose. The flow regulating valve is configured to control flow of the liquid refrigerant into the refrigeration circuit.

In some embodiments, the air bubble separator is located in the recharging circuit downstream from the filter.

In some embodiments, the recharging circuit is configured to provide the liquid refrigerant to the refrigeration circuit at a flow rate up to about 12 gallons per minute.

In some embodiments, the at least one outlet port comprises a plurality of outlet ports, each configured to be fluidly coupled to the refrigeration circuit via a respective hose. In other embodiments, the at least one outlet port comprises at least two outlet ports, each configured to be coupled to a hose having a different respective size. In other embodiments, the at least one outlet port comprises four outlet ports.

In some embodiments, at least a pair of wheels are rotatably coupled relative to the frame to facilitate mobility of the recharging apparatus.

In some embodiments, the reservoir comprises at least one inlet that is configured to be fluidly coupled to the refrigeration circuit such that refrigerant and air from the refrigeration circuit can flow into the reservoir during recharging operations.

According to some embodiments of the present invention, a method of recharging liquid refrigerant in a refrigeration circuit of a chiller system includes the following performed by a portable apparatus that is fluidly coupled to the chiller system: filtering liquid refrigerant to remove particulate matter therefrom, passing the filtered liquid refrigerant through an air bubble separator to remove air bubbles therefrom, and then recharging the refrigeration circuit with the liquid refrigerant. In some embodiments, the filtering, passing and recharging steps are performed at a flow rate up to about 12 gallons per minute.

Embodiments of the present invention are advantageous because the portable recharging apparatus is compatible with refrigeration circuits of different manufacturers. Moreover, the portable recharging apparatus can be used to recharge refrigeration circuits in chillers for both solar inverters and wind turbines.

It is noted that aspects of the invention described with respect to one embodiment may be incorporated in a different embodiment although not specifically described relative thereto. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination. Applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to be able to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner. These and other objects and/or aspects of the present invention are explained in detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which form a part of the specification, illustrate various embodiments of the present invention. The drawings and description together serve to fully explain embodiments of the present invention.

FIG. 1 schematically illustrates a chiller utilized to cool power conversion systems for solar and wind power generation applications.

FIG. 2A is a front view of a portable apparatus for recharging liquid refrigerant in a refrigeration circuit of a chiller system, according to some embodiments of the present invention.

FIG. 2B is a rear view of the portable recharging apparatus of FIG. 2A.

FIG. 3 illustrates the portable recharging apparatus of FIG. 2A connected to a chiller of a power conversion system for recharging the liquid refrigeration circuit therein.

FIG. 4 is a schematic diagram of the portable recharging apparatus of FIGS. 2A-2B.

FIG. 5 is a flow chart illustrating a method of recharging liquid refrigerant in a refrigeration circuit of a chiller system, according to some embodiments of the present invention.

DETAILED DESCRIPTION

The present invention will now be described more fully hereinafter with reference to the accompanying figures, in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Like numbers refer to like elements throughout. In the figures, certain layers, components or features may be exaggerated for clarity, and broken lines illustrate optional features or operations unless specified otherwise. In addition, the sequence of operations (or steps) is not limited to the order presented in the figures and/or claims unless specifically indicated otherwise. Features described with respect to one figure or embodiment can be associated with another embodiment or figure although not specifically described or shown as such.

It will be understood that when a feature or element is referred to as being “on” another feature or element, it can be directly on the other feature or element or intervening features and/or elements may also be present. In contrast, when a feature or element is referred to as being “directly on” another feature or element, there are no intervening features or elements present. It will also be understood that, when a feature or element is referred to as being “secured”, “connected”, “attached” or “coupled” to another feature or element, it can be directly secured, directly connected, attached or coupled to the other feature or element or intervening features or elements may be present. In contrast, when a feature or element is referred to as being, for example, “directly secured”, “directly connected”, “directly attached” or “directly coupled” to another feature or element, there are no intervening features or elements present. The phrase “in communication with” refers to direct and indirect communication. Although described or shown with respect to one embodiment, the features and elements so described or shown can apply to other embodiments.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.

As used herein, the terms “comprise”, “comprising”, “comprises”, “include”, “including”, “includes”, “have”, “has”, “having”, or variants thereof are open-ended, and include one or more stated features, integers, elements, steps, components or functions but does not preclude the presence or addition of one or more other features, integers, elements, steps, components, functions or groups thereof. Furthermore, as used herein, the common abbreviation “e.g.”, which derives from the Latin phrase “exempli gratia,” may be used to introduce or specify a general example or examples of a previously mentioned item, and is not intended to be limiting of such item. The common abbreviation “i.e.”, which derives from the Latin phrase “id est,” may be used to specify a particular item from a more general recitation.

As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items and may be abbreviated as “/”.

As used herein, phrases such as “between X and Y” and “between about X and Y” should be interpreted to include X and Y. As used herein, phrases such as “between about X and Y” mean “between about X and about Y.” As used herein, phrases such as “from about X to Y” mean “from about X to about Y.”

Spatially relative terms, such as “under”, “below”, “lower”, “over”, “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if a device in the figures is inverted, elements described as “under” or “beneath” other elements or features would then be oriented “over” the other elements or features. Thus, the exemplary term “under” can encompass both an orientation of over and under. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. Similarly, the terms “upwardly”, “downwardly”, “vertical”, “horizontal” and the like are used herein for the purpose of explanation only unless specifically indicated otherwise.

It will be understood that although the terms first and second are used herein to describe various features or elements, these features or elements should not be limited by these terms. These terms are only used to distinguish one feature or element from another feature or element. Thus, a first feature or element discussed below could be termed a second feature or element, and similarly, a second feature or element discussed below could be termed a first feature or element without departing from the teachings of the present invention.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the specification and relevant art and should not be interpreted in an idealized or overly formal sense unless expressly so defined herein. Well-known functions or constructions may not be described in detail for brevity and/or clarity.

The term “about”, as used herein with respect to a value or number, means that the value or number can vary by +/−twenty percent (20%).

The terms “hose” and “tubing”, as used herein, are intended to be interchangeable and refer to any type of conduit or line, flexible or otherwise, configured to convey fluid.

Referring to FIGS. 2A-2B, 3 and 4, a portable apparatus 100 for recharging liquid refrigerant, such as a glycol/water mixture (e.g., a 50%/50% glycol/water mixture, etc.), in a refrigeration circuit of a chiller system is illustrated. The recharging apparatus 100 includes a frame 102 with a plurality of wheels 104 rotatably coupled to the frame to facilitate mobility of the recharging apparatus 100. In some embodiments, at least a pair of wheels 104 are utilized. A reservoir 110 and a recharging circuit 120 are mounted to the frame 102. The reservoir 110 contains a liquid refrigerant for use in recharging the refrigeration circuit of a chiller, as will be described below. The recharging circuit 120 is fluidly coupled to the reservoir 110 and is configured to receive the liquid refrigerant from the reservoir for delivery to the refrigeration circuit of a chiller.

The recharging circuit 120 includes a filter 122 that is configured to remove particulate matter from the liquid refrigerant and an air bubble separator 124 that is configured to remove air bubbles from the liquid refrigerant before it is delivered to the refrigeration circuit of a chiller. The filter 122 is a heavy duty/high flow particulate filter. An exemplary filter that may be utilized as the filter 122 is the GE Appliance Heavy Duty/High Flow Filtration System, Model #GXWH40L, available from the General Electric Company, Boston, Mass. An exemplary air bubble separator that may be utilized as the air bubble separator 124 is a Bell & Gossett Air Separator ¾″ NPT Bronze 12 gpm (gallon per minute) Model #EASB 3/4JR, available from Bell & Gossett, Morton Grove, Ill.

The recharging circuit 120 also includes a pump 126, a flow regulating valve 128, and a manifold 130 having a plurality of outlet ports 132 a-132 d. Each outlet port 132 a-132 d is configured to be fluidly coupled to the refrigeration circuit of a chiller via a hose 140. In the illustrated embodiment, there are four outlet ports 132 a, 132 b, 132 c, 132 d. However, the manifold 130 may have less than four outlet ports or more than four outlet ports in other embodiments. Each of the illustrated outlet ports 132 a-132 d is a “quick connect” fitting that is an industry standard size. These “quick connect” outlet ports 132 a-132 d allow hoses of different sizes to be quickly connected and disconnected by hand and without the need for tools.

In some embodiments, each of the plurality of outlet ports 132 a-132 d is configured to be coupled to a hose having a respective different size. In other embodiments, at least two of the outlet ports 132 a-132 d are each configured to be coupled to a hose having a different respective size. As such, the portable apparatus 100 may be utilized to service various types of refrigeration circuits, regardless of chiller manufacturer.

In some embodiments, the reservoir 110 has a twelve gallon capacity. Typically, refrigeration circuits of chillers for inverters have a fifteen gallon refrigerant capacity. As such, a twelve gallon capacity reservoir 110 is sufficient to recharge such refrigeration circuits while remaining small enough for portability.

The reservoir 110 also includes one or more inlets 110 i (FIG. 2B) that are configured to be fluidly coupled to the refrigeration circuit of a chiller such that refrigerant and/or air from the refrigeration circuit can be bled back into the reservoir 110 during recharging operations. In the illustrated embodiment of FIG. 2B, the reservoir 110 is provided with two such inlets 110 i. The inlet 110 i on the left in FIG. 2B is connected to a hose or “purge line” 150 (FIG. 3) that is connected to the refrigeration circuit of a chiller. The purpose of the purge line 150 is to help remove air and to allow the flow of liquid refrigerant back to the reservoir 110 as part of a recharging procedure. The inlet 110 i on the right in FIG. 2B is connected to a hose or “bleeder line” 152 (FIG. 3) that is connected to the refrigeration circuit of a chiller. The purpose of the bleeder line 152 is to help remove air from the refrigeration circuit of the chiller.

The pump 126 is configured to pump the liquid refrigerant from the reservoir 110 through the filter 122 and the air bubble separator 124, and into the refrigeration circuit of a chiller via one or more hoses 140. An exemplary pump that may be utilized as the pump 126 is the Burks Close Coupled Turbine Pump-Series CR, Serial #T1881976, available from Crane Engineering, Kimberly, Wis. The flow regulating valve 128 is configured to control flow of the liquid refrigerant into the refrigeration circuit of the chiller. An exemplary flow regulator that may be utilized with the flow regulating valve 128 is the Square D Pressure switch, Model #2FH05, available from Schneider Electric SE, Rueil-Malmaison, France.

The pump 126 is powered by an electric motor (not shown) which is configured to receive electric power via a cable 160 connected to a power switch 162. The flow regulating valve 128 also receives electric power via the cable 160 and switch 162. In some embodiments, the pump 126 is configured to supply liquid refrigerant from the recharging circuit 120 to a refrigeration circuit of a chiller at a flow rate up to about 12 gallons per minute. However, other flow rates are possible.

In the illustrated embodiment, the air bubble separator 124 is located in the recharging circuit 120 downstream from the filter 122. However, embodiments of the present invention are not limited to such a configuration. In some embodiments, the air bubble separator 124 may be located in the recharging circuit 120 upstream from the filter 122.

Referring to FIG. 3, the portable recharging apparatus 100 of FIGS. 2A-2B is illustrated in operation. The portable recharging apparatus 100 is positioned adjacent to an inverter 200. A chiller unit associated with the inverter 200 services two modules (not shown) on the inverter 200. Each module has its own refrigeration circuit/heat exchanger. A first recharge hose 140 a is connected to a first one of these two refrigeration circuit/heat exchangers and a second recharge hose 140 b is connected to the second one of these two refrigeration circuit/heat exchangers, as illustrated. The purge line 150 and bleeder line 152 are also connected to the refrigeration circuit, as illustrated.

The portable recharging apparatus 100 is connected to an electric power source to power the pump 126 and flow control valve 128 via a cable 170 that is plugged into the power cable 160 for the apparatus 100. Recharging occurs from bottom-to-top in that liquid refrigerant is pumped from the reservoir 110 through the first and second recharge hoses 140 a, 140 b into the refrigeration circuits of the chiller of the inverter 200 and then out through the purge and bleeder lines 150, 152 back into the reservoir 110. This procedure involves filtering the liquid refrigerant via the filter 122 (Block 300, FIG. 5), removing air bubbles from the liquid refrigerant via air bubble separator 124 (Block 310, FIG. 5), and recharging the refrigeration circuit of the chiller for the inverter 200 with the liquid refrigerant that is free of impurities, air, and debris (Block 320, FIG. 5).

The foregoing is illustrative of the present invention and is not to be construed as limiting thereof. Although a few exemplary embodiments of this invention have been described, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the claims. The invention is defined by the following claims, with equivalents of the claims to be included therein. 

That which is claimed is:
 1. A portable apparatus for recharging liquid refrigerant in a refrigeration circuit of a chiller system, the apparatus comprising: a reservoir; and a recharging circuit fluidly coupled to the reservoir and configured to receive a liquid refrigerant in the reservoir, wherein the recharging circuit comprises a filter configured to remove particulate matter from the liquid refrigerant, an air bubble separator configured to remove air bubbles from the liquid refrigerant, a pump, and at least one outlet port configured to be fluidly coupled to the refrigeration circuit via a hose; wherein the pump is configured to pump the liquid refrigerant from the reservoir through the filter and the air bubble separator, and into the refrigeration circuit via the hose.
 2. The apparatus of claim 1, wherein the liquid refrigerant comprises a mixture of glycol and water.
 3. The apparatus of claim 1, wherein the air bubble separator is located in the recharging circuit downstream from the filter.
 4. The apparatus of claim 1, wherein the recharging circuit further comprises a flow regulating valve configured to control a flow rate of the liquid refrigerant into the refrigeration circuit.
 5. The apparatus of claim 1, further comprising a frame, wherein the reservoir and recharging circuit are mounted to the frame.
 6. The apparatus of claim 5, further comprising at least a pair of wheels rotatably coupled relative to the frame.
 7. The apparatus of claim 1, wherein the at least one outlet port comprises a plurality of outlet ports, each outlet port configured to be fluidly coupled to the refrigeration circuit via a respective hose.
 8. The apparatus of claim 1, wherein the at least one outlet port comprises at least two outlet ports, each configured to be coupled to a hose having a different respective size.
 9. The apparatus of claim 1, wherein the at least one outlet port comprises four outlet ports.
 10. The apparatus of claim 1, wherein the reservoir comprises an inlet that is configured to be fluidly coupled to the refrigeration circuit such that refrigerant from the refrigeration circuit can flow into the reservoir.
 11. The apparatus of claim 1, wherein the recharging circuit is configured to provide the liquid refrigerant to the refrigeration circuit at a flow rate up to about 12 gallons per minute.
 12. A portable apparatus for recharging liquid refrigerant in a refrigeration circuit of a chiller system, the apparatus comprising: a frame; a reservoir mounted to the frame; and a recharging circuit mounted to the frame, wherein the recharging circuit is fluidly coupled to the reservoir and configured to receive a liquid refrigerant in the reservoir, and wherein the recharging circuit comprises a filter configured to remove particulate matter from the liquid refrigerant, an air bubble separator configured to remove air bubbles from the liquid refrigerant, a pump, at least one outlet port configured to be fluidly coupled to the refrigeration circuit via a hose, and a flow regulating valve configured to control a flow rate of the liquid refrigerant into the refrigeration circuit; wherein the pump is configured to pump the liquid refrigerant from the reservoir through the filter, the air bubble separator, and the flow regulating valve, and into the refrigeration circuit via the hose.
 13. The apparatus of claim 12, wherein the liquid refrigerant comprises a mixture of glycol and water.
 14. The apparatus of claim 12, wherein the air bubble separator is located in the recharging circuit downstream from the filter.
 15. The apparatus of claim 12, further comprising at least a pair of wheels rotatably coupled relative to the frame.
 16. The apparatus of claim 12, wherein the at least one outlet port comprises a plurality of outlet ports, each outlet port configured to be fluidly coupled to the refrigeration circuit via a respective hose.
 17. The apparatus of claim 12, wherein the at least one outlet port comprises at least two outlet ports, each configured to be coupled to a hose having a different respective size.
 18. The apparatus of claim 12, wherein the reservoir comprises an inlet that is configured to be fluidly coupled to the refrigeration circuit such that liquid refrigerant from the refrigeration circuit can flow into the reservoir.
 19. The apparatus of claim 12, wherein the recharging circuit is configured to provide the liquid refrigerant to the refrigeration circuit at a flow rate up to about 12 gallons per minute.
 20. A method of recharging liquid refrigerant in a refrigeration circuit of a chiller system, the method comprising: filtering liquid refrigerant to remove particulate matter therefrom; passing the filtered liquid refrigerant through an air bubble separator to remove air bubbles therefrom; and then recharging the refrigeration circuit of the chiller system with the liquid refrigerant.
 21. The method of claim 20, wherein the filtering, passing and recharging steps are performed by a portable apparatus that is fluidly coupled to the chiller system at a flow rate up to about 12 gallons per minute. 